Belt fabric



Jan. 3, 167 N. A.'rRusLow BELT FABRIC Filed June 24, 1965 .3 23297275/ J2 von e ...mq Milione M IDU IUI lll IDI mil EDI Imi w E E D U /ZE/J/4 /5/6 /7 Q E @U n ww I .EDU-.. ...DDD- .Ul-.UUE

INVENTOR. /VEA L A. 779061011/ ATTORNEY United States Patent O 3,296,062 BELT FABRIC Neal A. Truslow, Winnsboro, S.C., assignor to United States Rubberl Company, New York, N.Y., a corporation of New Jersey Filed .lune 24, 1965, Ser. No. 466,644 11 Claims. (Cl. 161-91) This invention relates to a high strength duck fabric useful as reinforcing for industrial =belting, as high strength tape such as automotive seat belts, and the like.

Industrial conveyor belts and power transmission belts are commonly made with a woven fabric carcass and an elastomeric wear surface such as natural or synthetic rubber, polyvinyl chloride resin, polyurethane rubber, or the like. The reinforcing fabric contributes a high measure of strength to the composite structure, but efforts have been continuous to increase the strength contributed by such reinforcing fabrics while at the same time reducing the weight and stiffness caused by such reinforcement, and l to limit the stretch of the composite structure by limiting the stretch of the reinforcing fabric.

In the past, fabrics of the type contemplated herein have been woven of a variety of different fibers in la variety of weaves. However they have generally been characterized by having tight weaves using two harnesses that require heavy looms. The majority of belt ducks for power transmission belts have been woven in plain weaves. Frequently in order to weave a sufficiently tight construction, it has been necessary to weave a lighter than desired fabric, and when this was done it was necessary to adhere several plies of fabric together to build up the strength desired in the finished belt.

Another belt duck which has been used in the past is that which is sometimes called solid-woven belting. This fabric requires a special loom, but the fabric is sufflciently heavy and strong that a single ply often will sufce as reinforcement for `a belt. Solid-woven belting fabrics normally are woven from more than one set of warps, and the weaves consist of some warps weaving normallyv While other binder warps are used to interlace through the fabric and thereby hold the entire construction together.

In a third type of fabric used to reinforce belts some warps have an appreciable float and other warps weave plain.

The instant invention relates to a novel type of fabric which is especially useful as a reinforcing fabric. The fabric in accordance with this invention comprises high strength multi-filament warp yarns having a twist multiple less than about 2.0, and weft yarns interlaced therewith. When the fabric is to be used for reinforcing rubber, plastic or the like, such as belts, the weft yarns are formed of a material to which the reinforcement adheres strongly. A variety of `materials are available which could be used for the high strength warp Warns; polyamide (nylon), polyester, glass and viscose lare suitable. Similarly a number of yarns suitable for use as wefts are known; for example viscose filaments, cotton, nylon treated with resorcinol formaldehyde latex to improve its adhesion to rubber, and the like would be satisfactory.

The warp and weft yarns yare interwoven in a weave in which each weft yarn appears on only one side of the fabric and alternate weft yarns oat predominantly on opposite sides of the fabric. The warp yarns, although they appear at opposite sides of the fabric to tie the aforesaid wefts to the fabric, nonetheless are disposed predominantly in the fabric center and regularly pass nteriorly of at least two consecutive weft yarns at each side of the fabric.

The reinforcing fabrics according to this invention have numerous advantages. Inasrnuch as the weft yarns float tively from 21 through 34.

Patented Jan. 3, 1967 ice predominantly at the surfaces of the fabric, the wefts can be chosen for their adhesion to the material to be reinforced while the warps can be selected to give the desired strength, stretch and other properties to the fabric. The warps have a very low crimp and consequently the fabric has a low stretch in the w-arp direction. Less material is used for a given length of fabric because of the low and uniform lcrimp. The fabric can be produced more cheaplyY because it can be produced on high speed automatic looms, and the fabric has better Hex endurance and a smooth surface hence it may be easily coated.

For a better understanding of this invention, reference should be had to the following detailed description of specific embodiments thereof, when read in conjunction with the accompanying drawings wherein:

FIG. l is a dobby chain draft, which -also represents the weave diagram, of one specic embodiment of fabric in accordance with this invention;

FIG. 2 is a drawing-in draft for the fabric of FIG. l;

FIG. 3 is a cross-section of the fabric illustrated in FIG. l taken along a section represented lby the line 3 3 of FIG. l;

FIG. 4 isa cross-section of the fabric illustrated in FIG. 1 taken along a section represented by the line 4 4 in FIG. 1;

FIG. 5 is a dobby chain draft, which also represents the weave diagram, of a second embodiment of a fabric in accordance with this invention;

FIG. 6 is a dobby chain draft, which also represents the weave diagram, of a third embodiment of a fabric in accordance with this invention, and

FIG. 7 is 4a dobby chain draft, which `also represents the weave diagram, of a fourth embodiment of a fabric in accordance with this invention.

Referring now to the drawings, and particularly to FIGS. l, 3 and 4, a reinforcing fabric based on a seven harness sateen weave chain draft repeating on seven warps and fourteen wefts is disclosed. For ease in understanding the invention, the seven horizontal positions on the dobby chain draft have been numbered consecutively from 11 through 17, and the fourteen vertical positions on the dobby chain draft have been numbered consecu- The numbers 11 through 17 each may be :considered to represent a warp yarn and the numbers 21 through 34 each may be considered to represent a weft yarn. As is customary in preparing these chain drafts, whenever a dark square appears in the diagram the particular warp yarn in whose row that dark square is found overlies the particular weft yarn in whose row that dark square is found.

Referring to FIGS. 3 and 4, it will be noted that, for example, warp 11 passes over wefts 21 and 22. It then passes under wefts 23, 25, 27, 29, 31 and 33, and in the Same distance it passes over wefts 24 and 26, but under weft 28, and over wefts 30, 32 and 34. Warp 12 passes over weft 22 and under weft 24. It then .passes over wefts 26, 28, 30, 32 and 34, and in the same distance it passes under wefts 21, 23, 25, 27, 29 -before passing over weft 31 and under weft 33. It will be noted from FIG. 3 that the odd numbered wefts, 21, 23, 25, 27, 29, 31 and 33 are disposed at the top of the fabric and even numbered wefts 22, 24, 26, 28, 30, 32 and 34 are disposed at the bottom of the fabric. In other words, alternative wefts are disposed on opposite sides of the fabric. Each weft is disposed only on its side of the fabric and does not appear in the surface of the opposite side of the fabric. Because of the remaining fabric construction, when weft 21, for example, passes under warp 11, it is still concealed on the bottom side of the fabric by the remaining yarns.

Referring to FIG. 4 the predominance of the wefts in the surfaces of the fabric will be apparent. Thus it will be seen that weft 21, for example, floats predominantly on the upper .surface of the fabric whereas weft 22 floats For the fabrics shown in the drawing, the weave factors are:

predominantly on the lower surface.

It will also be apparent from a consideration of FIG. 3 Drawing Number of Weave that the warps lie almost exclusively at the interior of 5 Figur@ Harness Used Factor the fabric. Thus considering warp 12, for example, it appears at the bottom surface of the fabric beneath weft gigg 24, and it appears at the top surface of the fabric above Fig: 6:11: 4 1:33 weft 31. Otherwise it remains in the center of the fabric. Fig- 7 3 1 50 The warps have very low crimp as will be apparent 10 from a conslderatlon Ofthe fars m Table The fabric cover is equal to the sum of the warp cover The fwepty'one Speel c "im o mien/[S liste 1 n Table I and weft cover multiplied by the weave factor: of fabrics 1n accordance with this invention will further illustrate the invention. Each fabric was woven: with Fabf1CC0Vef=(WafP COVef-I-Weft COVr) (weave factor) 5040 denier nylon multiilament yarns in the warp and The fabric-s disclosed in Table I are all heavy fabrics 6600 denier viscose rayon multilament yarns in the weft. and their weights range from to 60 ounces per square TABLE I Total Yarn Embodirnent Weave Warps Per Wefts Per Warp Cover Weft Cover Fabric Warp Yarn Weit Yarn Crimp (Sum of Figure Inch Inch Cover Crimp Crimp Warp Crimp Plus Weit Crimp) 7 27. 0 25. 0 24. 8 22.8 71. 5 19. 7 1. 2 20. 9 7 27. 2 21. 7 25.1 19. 7 67. 3 12. 2 2. 6 i4. 8 7 26. 7 19. 0 24. 6 17. 3 62. 8 12. 9 2. 3 15. 2 7 26. 0 26. 0 24.0 23. 7 71. 5 20. 0 2. 8 22.8 6 28.0 29.5 25.5 26.9 70.3 19.4 4.3 23.7 6 28.2 29.5 26.0 26.9 70.5 26.6 4.4 25.0 6 26.6 23.0 24.5 21.0 60.5 16.0 1.8 17.8 6 26. 6 23.6 24. 5 21. 5 61. 4 16. 4 1.9 18.3 6 27. 3 27.2 25. 1 24. 8 66. 5 20. 3 3. 6 23. 9 6 27. 3 28. 4 25. 1 25.9 68. 0 21.6 3.0 24. 6 6 17.5 18.7 16.1 17.0 44.1 7.6 1.7 9.3 6 16.8 15.9 15.5 14.5 40.0 7.3 1.7 9.0 6 17.7 20.1 16.3 18.3 46.2 8.7 3.0 11.7 5 26.6 22.8 24.8 20.8 56.6 7.1 4.4 11.5 5 26.3 25.0 24.2 22.8 58.7 7.2 6.4 13.6 5 27.7 26.8 25.5 24.4 62.3 8.1 5.8 13.9 5 27.3 29. 0 25. i 26. 4 64. 5 i2. 0 6. 0 18. 0 i 27.1 23.2 25.0 21.1 53.8 4.8 4.3 9.1 i 28.2 24.0 26.0 21.9 55.9 5.6 4.0 9.6 1 28.2 27.2 26.0 24.8 59.4 6.3 4.2 10.5 1 28.2 29.0 26.0 26.4 61.0 7.9 4.3 12.2

The Weave figure column indicates the figure of the yard. It will be noted that the fabric cover of the fabrics drawingin which the weave diagram for that particular given in Table I range from about for embodiment L fabric embodiment is shown. Thus the Weave diagram t0 abtOU 70 fOr mbQdmeHtS A, D, E, F and J- It iS Charfoiembodiment A is found in FIGS. 7 of the drawing, 45 acteristic of fabrics in accordance With this invention that that foi. embodiment E iI1 FIG' 6 that for embodiment the fabric cover will fall in this range. For fabrics which N in FIG. 5 and that for embodiment R in FIG. 1 The are to be coated with a polymeric material such as natural warps per inch? Wefts per inch, Warp yam crimp, grrnsyrrcitilliefgicrbbter er pllastitc 11n the manufiacture otfhbekllts and weft yarn crimp are all well known terms in the e s m um ar 1C es m accor. ance W1 t 1S te fi art and have their usual meanin s invention the fabric cover should be higher than the XTlhe i; s d i, ft g1' t minimum of 40. Such fabrics should have a fabric cover e War? Cover an We Cover ,cg umns re er Cf a in the range from 47 to 71. Fabrics with these higher Weuknown Index of the de gree of tlg mess or den'slty covers are not so easily distorted in handling and in 0f a band 01 Win13- (J- B- .Dlckson TeX. Res- 1954,' P- processing incident to further fabrication subsequent to 1083). This index consists lof the thread count, i.e. the Weaving thereo warps per inch or wefts per inch, as the Case may be, It will be noted also that the warp and weft crimps are divided by the product of the square root of the yarn size low in fabrics in accordance with this invention. The times the square root of the fiber density. The yarn size warp crimp is not greater than about 20%, as in Examples is given in cotton count for the calculation of this index A, D, E, F, I and I, and the total Yaln Crimp S Ilot greater 0f cover, For example, 60 than about 24%, as in embodiments E, F, I, and J. In a woven fabric it is possible to get `some interchange of (warps per inch) crimp between the warp and the weft. For example if a Warp COV1`=' l (N/yiiin sizdXM/density) fabric 1s tensioned in the warp direction and relaxed in the weft direction, it is often possible to reduce the It will be observed that these fabrics have very low WafP Crlmp and increase the Weft CTmP- For fabrics warp, weft and total crimp which are to be coated with a polymeric material such The fabric cover is an index of the degree of tight as natural or synthetic rubber or plastic in the manufacture ness of the fabrie To eaieuiate this index the Warp of belt and reinforced structural articles the crimp desirably cover is added to the weft cover and the resultant sum will be less; the larp cnmp Should be less than 18% and is multiplied by a weave factor. This weave factor theFItta15y]m cruilp Should .be less than 20%.' is derived from the number of interlacings of the yarn throu Q'sinovrigbtieeiwei'le dlagr'mdfor embodlments N in one repeat of the weave, and is calculated according g ese er. o lments are based on to the following equation 1a five harness sateen Weave which Irepeats on ve warps 41, 42, 43, 44 and 45 and ten wefts 51, 52, 53, 54, 55, Weave factor=1-{-1/ (number of harness-l) 75 56, 57, 58, 59 and 60 interlaced as shown in FIG. 5.

The fabrics of FIG. 6 are :based on a four harness twill weave which repeats on four warps 61, 62, 63 and 64 and eight Wefts 71, 72, 73, 74, 75, 76, 77 and 78 interlaced as shown in FIG. 6.

The fabrics of FIG. 7 are based on a three harness twill `weave which repeats on three warps 81, 82 and 83 and six wefts 91, 92, 93, 94, 95 and 96 interlaced as shown in FIG. 7.

The fabrics in accordance with this linvention are generally firm fabrics as is indicated by the Warp and weft covers and fabric covers of embodiments A through U in Table I. Further in the fabrics of this invention each yarn in the fabric oats over an average of at least two yarns throughout the fabric. Of course at the points of interlacing this float pattern does not obtain, but it does obtain as an average throughout the fabric. For some embodiments it is particularly desirable to -use a double-faced `sateen Weave such as shown in FIGS. 1 and 5 of the drawings. Such weaves often have a distinct twill line which can prevent straight tracking of a belt when they form the carcass fabric thereof, but this can be overcome by use of the pointed draw shown in FIG. 4. In many cases a straight draw can be used.

Having thus described my invention, what I claim and desire to protect by Letters Patent is:

1. A fabric comprising high strength multilament warp yarns having a twist multiple less than about 2.0, and weft yarns 'capable of being adhered strongly to a polymer coating interwoven with said wa-rp yarns, said warp and weft yarns being woven in ia weave in which both faces of the fabric are composed predominantly of weft yarns, and the Warp yarns being predominantly in the fabric center and regularly passing fon the fabric interior side of at least two consecutive weft yarns at each Side of the fabric.

2. A fabric in accordance with claim 1 in which the warp yarn crimp is not greater than about 20%.

3. A fabric in accordance with claim 2 in which the total yarn crimp in the fabric is not greater than about 24%.

4. A fabric in accordance with claim 3 in which the fabric cover is from Iabout to about 71.

5. A fabric in accordance with claim 4 in which the fabric cover is in the range from 47 to 71.

6. A fab-ric reinforced polymer belt having a reinforcing fabric constructed in accordance With claim 5.

7. A fabric in accordance with claim 1 in which the warp crimp is less than 18%.

8. A fabric in accordance with claim 7 in which the total yarn crimp is less than 20%.

9. A fabric in accordance with claim 8 in which the fabric cover is in the range of about 40 to about 71.

10. A fabric in accordance with cla-im 9 in which the fabric cover is in the range from 47 to 71.

11. A fabric reinforced polymer belt having a reinforcing fabric constructed in accordance with claim 10.

References Cited by the Examiner UNITED STATES PATENTS 1,227,427 '5/1917 Garbau et al. 161-91 2,090,547 8/11937 Neaves 139-426 2,866,483 12/1958 Watts et al 139-426 X 3,154,459 10/1964 Cranston 198-193 X FOREIGN PATENTS 848,005 9/ 1960 Great Britain.

MERVIN STEIN, Primary Examiner.

H. S. JAUDON, Assistant Examiner. 

1. A FABRIC COMPRISING HIGH STRENGTH MULTIFILAMENT WARP YARNS HAVING A TWIST MULTIPLE LESS THAN ABOUT 2.0, AND WEFT YARNS CAPABLE OF BEING ADHERED STRONGLY TO A POLYMER COATING INTERWOVEN WITH SAID WARP YARNS, SAID WARP AND WEFT BEING WOVEN IN A WEAVE IN WHICH BOTH FACES OF THE FABRIC ARE COMPOSED PREDOMINANTLY OF WEFT YARNS, AND THE WARP YARNS BEING PREDOMINANTLY IN THE FABRIC CENTER AND REGULARLY PASSING ON THE FABRIC INTERIOR SIDE OF AT LEAST TWO CONSECUTIVE WEFT AT EACH SIDE OF THE FABRIC. 